Apparatus and methods for automatically training saw blades on a saw mandrel

Abstract

Apparatus and methods for automatically training (i.e., straightening) saw blades along a saw mandrel are disclosed.

What is claimed is: 
     
       1. A method of automatically training saw blades along a saw mandrel comprising multiple saw blades, said method comprising:
 positioning a gauge relative to a first saw blade along a saw mandrel such that left and right gauge contact members of the gauge extend along opposite left and right major surfaces of the first saw blade, respectively, and the first saw blade is between the left and right gauge contact members; and 
 in response to the first saw blade touching at least one of the left and right gauge contact members during rotation of the saw mandrel,
 bending the first saw blade in a right direction if the first saw blade touches the left gauge contact member, and bending the first saw blade in a left direction if the first saw blade touches the right gauge contact member. 
 
 
     
     
       2. The method of  claim 1 , further comprising:
 positioning a bender relative to the first saw blade such that left and right bender contact members of the bender extend along the opposite left and right major surfaces of the first saw blade, respectively, and the first saw blade is between the left and right bender contact members; and 
 rotating the saw mandrel. 
 
     
     
       3. The method of  claim 2 , further comprising:
 in response to the first saw blade not touching the left or right gauge contact members during at least one complete rotation of the saw mandrel,
 moving the gauge and the bender away from the first saw blade such that the left and right gauge contact members of the gauge and the left and right bender contact members of the bender do not extend along the opposite left and right major surfaces of the first saw blade; 
 subsequently moving the gauge and the bender along the saw mandrel a distance equal to a spacing between adjacent saw blades; and 
 moving the gauge and the bender toward a second saw blade of the saw mandrel such that the left and right gauge contact members of the gauge and the left and right bender contact members of the bender extend along opposite left and right major surfaces of the second saw blade. 
 
 
     
     
       4. The method of  claim 3 , further comprising:
 in response to the second saw blade touching at least one of the left and right gauge contact members during rotation of the saw mandrel,
 bending the second saw blade in a right direction if the second saw blade touches the left gauge contact member, and bending the second saw blade in a left direction if the second saw blade touches the right gauge contact member. 
 
 
     
     
       5. The method of  claim 1 , further comprising:
 providing an electrical current through the saw mandrel and the left and right gauge contact members of the gauge such that (i) contact of the first saw blade with the left gauge contact member of the gauge completes a first circuit and send a first signal to a programmable logic controller, and (ii) contact of the first saw blade with the right gauge contact member of the gauge completes a second circuit and send a second signal to the programmable logic controller. 
 
     
     
       6. The method of  claim 5 , further comprising:
 in response to the programmable logic controller receiving the first signal,
 sending a first command to the bender so as to cause the bender to bend the first saw blade in the right direction; and 
 
 in response to the programmable logic controller receiving the second signal,
 sending a second command to the bender so as to cause the bender to bend the first saw blade in the left direction. 
 
 
     
     
       7. The method of  claim 2 , wherein the bender is positioned directly opposite the gauge relative to the saw mandrel such that any point along the first saw blade that touches the left or right gauge contact member of the gauge travels 180° during rotation of the saw mandrel so as to be positioned between the left and right bender contact members of the bender. 
     
     
       8. A method of automatically training saw blades along a saw mandrel, said method comprising:
 rotating a saw mandrel comprising multiple saw blades spaced from one another along the saw mandrel; and 
 in response to a first saw blade not touching left or right gauge contact members of a gauge during at least one complete rotation of the saw mandrel and while the gauge is in an activated position,
 moving the gauge into a deactivated position via a programmable logic controller; and 
 subsequently moving the gauge and a bender along the saw mandrel a distance equal to a spacing between adjacent saw blades via the programmable logic controller. 
 
 
     
     
       9. The method of  claim 8 , further comprising:
 in response to the first saw blade touching at least one of the left and right gauge contact members of the gauge during rotation of the saw mandrel and while the gauge is in an activated position,
 bending the first saw blade in a right direction if the first saw blade touches the left gauge contact member, and bending the first saw blade in a left direction if the first saw blade touches the right gauge contact member. 
 
 
     
     
       10. The method of  claim 9 , further comprising:
 positioning the gauge relative to the first saw blade along the saw mandrel such that the left and right gauge contact members of the gauge extend along opposite left and right major surfaces of the first saw blade, respectively, and teeth of the first saw blade are between the left and right gauge contact members; and 
 positioning a bender relative to the first saw blade such that left and right bender contact members of the bender extend along the opposite left and right major surfaces of the first saw blade, respectively, and teeth of the first saw blade are between the left and right bender contact members. 
 
     
     
       11. An apparatus for performing the method of  claim 1 , said apparatus comprising:
 the gauge comprising the left and right gauge contact members; 
 a bender comprising left and right bender contact members; and 
 an apparatus component operatively adapted to move the left and right bender contact members relative to the first saw blade. 
 
     
     
       12. An apparatus for performing the method of  claim 8 , said apparatus comprising:
 a support structure operatively adapted to support and allow rotation of a saw mandrel; 
 a motor and associated connecting components operatively adapted to rotate the saw mandrel; 
 the gauge comprising the left and right gauge contact members; and 
 the programmable logic controller. 
 
     
     
       13. An apparatus for automatically training saw blades along a saw mandrel, said apparatus comprising:
 a gauge comprising left and right gauge contact members, said left and right gauge contact members being spaced from one another so as to be positionable along opposite left and right major surfaces of a first saw blade positioned along a saw mandrel such that teeth of the first saw blade are between the left and right gauge contact members; and 
 a bender comprising left and right bender contact members, said left and right bender contact members being spaced from one another so as to be positionable along the opposite left and right major surfaces of the first saw blade such that teeth of the first saw blade are between the left and right bender contact members, 
 wherein in response to the first saw blade touching at least one of said left and right gauge contact members during rotation of the saw mandrel, said bender being operatively adapted to (i) bend the first saw blade in a right direction if the first saw blade touches the left gauge contact member, and (ii) bend the first saw blade in a left direction if the first saw blade touches the right gauge contact member. 
 
     
     
       14. The apparatus of  claim 13 , wherein the bender is positioned directly opposite the gauge relative to the saw mandrel such that any point along the first saw blade that touches the left or right gauge contact member of the gauge travels 180° during rotation of the saw mandrel so as to be positioned between the left and right bender contact members of the bender. 
     
     
       15. The apparatus of  claim 13 , further comprising:
 one or more apparatus components operatively adapted to move the gauge and the bender toward or away from the first saw blade. 
 
     
     
       16. The apparatus of  claim 13 , further comprising:
 a support structure operatively adapted to support and allow rotation of a saw mandrel; 
 a first motor and associated connecting components operatively adapted to rotate the saw mandrel when positioned within the support structure; 
 a ball screw extending parallel to the saw mandrel when positioned within the support structure; 
 a second motor and associated connecting components operatively adapted to rotate the ball screw; and 
 a movable support structure operatively adapted to (i) support the gauge and the bender, and (ii) move along the ball screw. 
 
     
     
       17. The apparatus of  claim 16 , further comprising:
 a first gear coaxially positioned along said ball screw; 
 a second gear in rotationable contact with said first gear; and 
 a gear sensor operatively adapted to detect a position of said second gear, 
 wherein one complete rotation of said second gear moves said movable support structure a distance along said ball screw equal to a spacing between adjacent saw blades. 
 
     
     
       18. The apparatus of  claim 13 , further comprising:
 a sprocket coaxially positioned along the saw mandrel; and 
 a sprocket sensor operatively adapted to detect a rotating position along said sprocket relative to said sprocket sensor. 
 
     
     
       19. The apparatus of  claim 13 , further comprising:
 an electrical current through the saw mandrel such that (i) contact of the first saw blade with the left gauge contact member of the gauge completes a first circuit and generates a first signal, and (ii) contact of the first saw blade with the right gauge contact member of the gauge completes a second circuit and generates a second signal; and 
 a programmable logic controller operatively adapted to receive said first and second signals, and in response to receiving the first signal, sending a first command to the bender so as to cause the bender to bend the first saw blade in the right direction, and in response to receiving the second signal, sending a second command to the bender so as to cause the bender to bend the first saw blade in the left direction. 
 
     
     
       20. The apparatus of  claim 13 , wherein the bender is positioned directly opposite the gauge relative to the saw mandrel such that any point along the first saw blade that touches the left or right gauge contact member of the gauge travels 180° during rotation of the saw mandrel so as to be positioned between the left and right bender contact members of the bender, and said apparatus further comprises:
 one or more apparatus components operatively adapted to move the gauge and the bender toward or away from the first saw blade; 
 a support structure operatively adapted to support and allow rotation of a saw mandrel; 
 a first motor and associated connecting components operatively adapted to rotate the saw mandrel when positioned within the support structure; 
 a ball screw extending parallel to the saw mandrel when positioned within the support structure; 
 a second motor and associated connecting components operatively adapted to rotate the ball screw; 
 a movable support structure operatively adapted to (i) support the gauge and the bender, and (ii) move along the ball screw; 
 a first gear coaxially positioned along said ball screw; 
 a second gear in rotationable contact with said first gear; 
 a gear sensor operatively adapted to detect a position of said second gear, wherein one complete rotation of said second gear moves said movable support structure a distance along said ball screw equal to a spacing between adjacent saw blades; 
 a sprocket coaxially positioned along the saw mandrel; 
 a sprocket sensor operatively adapted to detect a rotating position along said sprocket relative to said sprocket sensor; 
 an electrical current through the saw mandrel such that (i) contact of the first saw blade with the left gauge contact member of the gauge completes a first circuit and generates a first signal, and (ii) contact of the first saw blade with the right gauge contact member of the gauge completes a second circuit and generates a second signal; and 
 a programmable logic controller operatively adapted to receive said first and second signals, and in response to receiving the first signal, sending a first command to the bender so as to cause the bender to bend the first saw blade in the right direction, and in response to receiving the second signal, sending a second command to the bender so as to cause the bender to bend the first saw blade in the left direction.